Cooling module in a motor vehicle

ABSTRACT

A cooling module in a motor vehicle may include at least one heat exchanger block and at least one holding device. The at least one holding device may secure the cooling module on the vehicle body. The at least one holding device may be designed as a cast component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to German Patent Application No. 10 2015 209 206.2, filed May 20, 2015, the contents of which are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

The present invention relates to a cooling module in a motor vehicle, with at least one heat exchanger block and at least one holding device for securing said cooling module on a vehicle body. The invention also relates to a motor vehicle with at least one such cooling module.

BACKGROUND

DE 100 18 001 A1 discloses a cooling module with a charge air cooler and a coolant cooler. The charge air cooler is arranged in this case parallel to the coolant cooler. The charge air boxes of the charge air cooler are extended at their ends as far as the coolant boxes of the coolant cooler and are screwed directly to the coolant boxes. The charge air boxes of the charge air cooler and the coolant boxes of the coolant cooler thereby form a stable supporting frame for the entire cooling module, which supporting frame is intended to be able to anchored in the vehicle in a simple manner.

For the connection of cooling modules to vehicle bodies of a motor vehicle, use is generally made of what are referred to as module holders which are connected fixedly to a U-shaped steel profile which, in turn, surrounds the cooling module or individual parts thereof. The components necessary for the application-specific mounting of the cooling module comprise two steel coverings as U-profiles with punched-out portions for the flow of cooling air, main module holders with rubber insulators and hinged supports for absorbing moments due to inertia forces or reaction forces, and also necessary fastening elements. The U-shaped steel profiles in this case frequently have a thickness of approx. 2.5 mm and are produced from coil or sheet bar material in a plurality of punching and forming steps. In order to avoid damage due to corrosion, said steel profiles customarily have to be coated in a suitable process, for example cathodically dip-coated.

However, a disadvantage of the steel profiles known from the prior art is that said steel profiles are produced from a wall material with a constant wall thickness and, as a result, can be adapted only to a very limited extent, if at all, to local stress peaks by means of a local change in shape. The rigidity of the U-shaped steel profiles is influenced here by the limb height and the material thickness. However, the demand for an unimpeded incident flow to the cooler surface necessitates punched-out portions in the limbs of the U-shaped steel profile, which in turn leads to a relatively large amount of waste and to an inefficient use of the main material. Furthermore, the corrosion protection which is always required can be applied only in a further process, as a result of which the costs are increased in turn.

SUMMARY

Therefore, the present invention is concerned with the problem of specifying, for a cooling module of the type in question, an improved or at least an alternative embodiment which is distinguished in particular by a more cost-effective manner of production.

This problem is solved according to the invention by the subject matter of the independent claims. Advantageous embodiments are the subject matter of the dependent claims.

The present invention is based on the general concept of designing a holding device for securing a cooling module on a vehicle body of a motor vehicle not, as hitherto, as a steel profile, which is awkward and expensive to produce, but for the first time as a cast component, thus introducing the possibility of designing the cooling module not only cost-effectively but also in an optimized manner with respect to the forces acting on the holding device. By means of the design according to the invention of the holding device as a cast component, it is also possible to integrate all of the hitherto separate components of a holding device of this type, such as, for example, the U profile, holders for hinged supports and additional screw-on points, now for the first time in a single component, as a result of which not only is it possible to dispense with the hitherto complicated, since separate, manufacturing of the individual components, but in addition also the comparatively cost-intensive installation thereof. By means of the holding device according to the invention designed as a cast component, even local changes in thickness can be realized comparatively simply, as a result of which the holding device can be adapted individually to the forces acting thereon. This effect can be reinforced, for example, by stiffening ribs which are formed or cast integrally with the holding device and, with a comparatively low weight, permit a load-specific configuration of the holding device.

In an advantageous development of the solution according to the invention, the at least one holding device is designed as an aluminium cast component. The use of an aluminium material makes it possible to entirely dispense with a hitherto required corrosion protection layer to be applied separately, for example by means of cathodic dip-coating, which likewise contributes to a reduction in the production costs. Alternatively, the at least one holding device can also be designed as an injection-moulded plastics component. This constitutes a solution which is again weight-optimized and which is also extremely cost-effective. An injection-moulded plastics component is particularly advantageous with regard to corrosion protection.

In an advantageous development of the solution according to the invention, at least one holding device has at least one first connecting tab for connecting to the vehicle body. A first connecting tab of this type can have, for example, a through opening and therefore a screw-on point. Of course, it is possible in the same manner also to provide a second connecting tab for connecting to a hinged support, said connecting tab in turn being able to have a through opening via which the hinged support can be screwed on in a simple manner. A particular advantage of the holding device designed according to the invention as a cast component is that the number and orientation and also configuration of the individual connecting tabs can be realized in a simple manner by a corresponding design of the casting mould, specifically irrespective of whether the holding device is designed as a metallic cast component or as an injection-moulded plastics component. In comparison to a holding device hitherto designed as a U-shaped steel profile, in the case of the holding device according to the invention the connecting tabs can also be arranged in virtually any angular position. By this means, a particularly flexible and load-specific design of the holding device is possible.

In a further advantageous embodiment of the solution according to the invention, the cooling module has a coolant cooler, in which associated coolant collecting boxes are at least partially formed from plastic. By this means, it is possible to produce part of the coolant cooler comparatively cost-effectively, in particular in the manner of an injection-moulded plastics part, as a result of which a reduction in cost can likewise be achieved.

In an advantageous development of the invention, the cooling module is designed as a direct charge air cooler and has a high-temperature coolant cooler, or the cooling module is designed as an indirect charge air cooler and has both a high-temperature coolant cooler and a low-temperature coolant cooler. The abovementioned possibilities already show that the holding device which, according to the invention, is designed as a cast component, does not have to be restricted per se to a certain type of cooler module, but rather can be used for a very wide variety of embodiments of a cooling module or cooler.

The at least one holding device expediently has integrally formed stiffening ribs. By this means, it is possible to adapt the moment of resistance of the holding device to the requirements in the driving mode and thereby to be able to optimally absorb the accelerations and reaction forces occurring therein. The stiffening ribs can be realized here in a comparatively simple and cost-effective manner by means of a corresponding configuration of the casting mould.

Further important features and advantages of the invention emerge from the dependent claims, from the drawings and from the associated description of the figures with reference to the drawings.

It goes without saying that the features mentioned above and those which have yet to be explained below can be used not only in the respectively stated combination, but also in different combinations or on their own without departing from the scope of the present invention.

Preferred exemplary embodiments of the invention are illustrated in the drawings and are explained in more detail in the description below, wherein the same reference signs refer to identical or similar or functionally identical components.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, in each case schematically,

FIG. 1 shows a first view of a cooling module according to the invention in a motor vehicle with a holding device designed according to the invention as a cast component,

FIG. 2 shows an illustration as in FIG. 1, but from a different perspective,

FIG. 3 shows a view of the holding device according to the invention,

FIGS. 4, 5 show further views of the holding device according to the invention.

DETAILED DESCRIPTION

According to FIGS. 1 and 2, a cooling module 1 according to the invention, which can be fitted, for example, in a motor vehicle 11, has at least one heat exchanger block 2 and at least one holding device 3 for securing said cooling module on a vehicle body 12 (only illustrated in highly schematized form in FIG. 2). According to the invention, this holding device 3 is now designed as a cast component, in particular as an aluminium cast component or as an injection-moulded plastics component. In comparison to a holding device hitherto produced from a punched and formed steel profile, this introduces the great possibility of designing the holding device 3 not only to be more cost-effective but in particular also in optimized form to the loads to be absorbed in the operating state. For example, it is possible to form a plurality of components, such as, for example, a wide variety of connecting tabs 4, 5, 6, 7, integrally with the holding device 3, as a result of which the hitherto required separate manufacturing and the subsequent installation can be omitted. A connection to the vehicle body 12 can take place here via a first connecting tab 4, whereas, for example, a connection to a hinged support (not shown) for compensating for transverse acceleration forces can take place via a second connecting tab 5.

The holding device 3 can be designed here as an integral injection-moulded plastics part consisting of the same material throughout, or else as an injection-moulded plastics part with at least one injected insert, in particular with injected reinforcing elements, such as glass fibres/carbon fibres, or with an injected aluminium cast part, for example a threaded bushing. By this means, it is possible to integrate functional components which can be subjected to higher loads, such as, for example, threads, eyelets, bushings, etc., in a simple but nevertheless reliable manner in the holding device 3. In this case, the holding device 3 is therefore designed as a composite component.

In general, the cooling module 1 according to the invention can have a high-temperature coolant cooler 9 and a low-temperature coolant cooler 8. Alternatively, the cooling module 1 can also have a direct charge air cooler and only a high-temperature coolant cooler 9. For the connection to the high-temperature coolant cooler 9, at least one third connecting tab 6 can be provided on the holding device 3, whereas, for the connection of the holding device 3 to the low-temperature coolant cooler 8, a fourth connecting tab 7 can be provided.

In order to be able optimally to transmit the forces which occur in the operating state and are to be absorbed in particular by the holding device 3, the at least one holding device 3 can have integrally formed stiffening ribs 10 (cf. in particular FIGS. 1 to 3), wherein the orientation and also the strength of the stiffening ribs 10 can be adapted to the loads occurring individually in each case in this region. The stiffening ribs 10 can be realized in a comparatively simple manner here by a corresponding casting mould.

The at least one holding device 3 is preferably designed as an aluminium cast component or as an injection-moulded plastics component, as a result of which it is possible to dispense with corrosion protection which has hitherto been required and is complicated to apply, for example by means of cathodic dip-coating. By this means, the holding device 3 according to the invention and therefore also the cooling module 1 according to the invention can be produced more cost-effectively.

In a further advantageous embodiment of the solution according to the invention, the cooling module 1 has a coolant cooler, for example a low-temperature coolant cooler 8, in which associated coolant collecting boxes are at least partially formed from plastic. By this means, it is possible to produce part of the coolant cooler comparatively cost-effectively, in particular in the manner of an injection-moulded plastics part, as a result of which a reduction in costs can likewise be achieved.

By means of the holding device 3 designed according to the invention as a cast component, not only can advantages therefore be achieved in respect of the corrosion protection, but also a very wide variety of intersections for the connection can be integrated in the holding device 3 in a comparatively simple manner. The intersections here are the corresponding connecting tabs 4 to 7. Furthermore, the holding device 3 according to the invention permits simplified production and can be used for all types of cooling modules 1 in particular also with LT/HT coolant coolers 8, 9, for example also charge air coolers.

Of course, the holding device 3 according to the invention can also be provided as an individual part, in particular for repair situations. The stiffening ribs 10 also make it possible to achieve a special load-specific stiffening, in particular of the connecting tabs 4 to 7, and a simultaneously comparatively low weight. 

1. A cooling module in a motor vehicle, comprising: at least one heat exchanger block; and at least one holding device for securing said cooling module on a vehicle body, wherein the at least one holding device is a cast component.
 2. A cooling module according to claim 1, wherein the at least one holding device is one of: an aluminium cast component, or an injection-moulded plastics component.
 3. A cooling module according to claim 1, wherein the at least one holding device is one of: an injection-moulded plastics part having the same material throughout, or an injection-moulded plastics part with one of at least one injected insert or an injected aluminium cast part.
 4. A cooling module according to claim 1, wherein the at least one holding device has at least one connecting tab for connecting to the vehicle body.
 5. A cooling module according to claim 1, wherein the at least one holding device has at least one connecting tab for connecting to a hinged support.
 6. A cooling module according to claim 1, further comprising one of: a direct charge air cooler and a high-temperature coolant cooler, or a high-temperature coolant cooler and a low-temperature coolant cooler.
 7. A cooling module according to claim 6, wherein at least one of: the at least one holding device has at least one connecting tab for connecting to the high-temperature coolant cooler, and the at least one holding device has at least one connecting tab for connecting to the low-temperature coolant cooler.
 8. A cooling module according to claim 1, wherein the at least one holding device has integrally formed stiffening ribs.
 9. A Motor vehicle comprising at least one cooling module having: at least one heat exchanger block; and at least one holding device for securing said cooling module on a vehicle body, wherein the at least one holding device is a cast component.
 10. A cooling module in a motor vehicle, comprising: at least one heat exchanger block; a high-temperature coolant cooler; one of a direct charge air cooler or a low-temperature coolant cooler; and at least one holding device for securing said cooling module on a vehicle body, the at least one holding device having at least one first connecting tab for connecting to the vehicle body, at least one second connecting tab for connecting to a hinged support, and at least one third connecting tab for connecting to the high-temperature coolant cooler; wherein the at least one holding device is a cast component.
 11. A cooling module according to claim 10, wherein the at least one holding device is one of an aluminium cast component or as an injection-moulded plastics component.
 12. A cooling module according to claim 10, wherein the at least one holding device is one of: an injection-moulded plastics part having the same material throughout, or an injection-moulded plastics part with one of at least one injected insert or an injected aluminium cast part.
 13. A cooling module according to claim 12, wherein at least one of: the at least one injected insert includes at least one of glass fibres and carbon fibres, and the injected aluminium cast part is a threaded bushing.
 14. A cooling module according to claim 10, wherein the at least one holding device includes at least one fourth connecting tab for connecting to the low-temperature coolant cooler.
 15. A cooling module according to claim 10, wherein the at least one holding device has integrally formed stiffening ribs.
 16. A cooling module according to claim 3, wherein at least one of: the at least one injected insert includes at least one of glass fibres and carbon fibres, and the injected aluminium cast part is a threaded bushing.
 17. A cooling module according to claim 2, wherein the at least one holding device has at least one first connecting tab for connecting to the vehicle body.
 18. A cooling module according to claim 17, wherein the at least one holding device has at least one second connecting tab for connecting to a hinged support.
 19. A cooling module according to claim 3, wherein the at least one holding device has at least one first connecting tab for connecting to the vehicle body.
 20. A cooling module according to claim 19, wherein the at least one holding device has at least one second connecting tab for connecting to a hinged support. 